Vertical Trim Panel with Integrated Stitching

ABSTRACT

A method of forming a panel is disclosed. The method comprises forming a flexible skin; coupling a compressible material to the skin; providing a stitching to the skin and compressible material combination; then positioning the skin and compressible material in a mold; and forming a rigid substrate around the skin and compressible material and a portion of the stitching for providing a first soft region wherein the compressible material is disposed between the skin and the substrate so that a first soft region is defined by the compressible material.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

The present PCT Application claims priority under U.S. Provisional Application No. 60/632,997, entitled MOLDED ARTICLE WITH STITCHING, filed on Dec. 3, 2004, the fall disclosure of which is hereby incorporated herein by reference.

BACKGROUND

The present application relates to the field of molded articles having soft portions with stitching, embroidery and/or other sewn portions (which will collectively be referred to as “stitching”). More specifically, the present application further relates to interior trim panels or structures for vehicles (e.g., automobiles such as cars, trucks, and the like; airplanes, boats, etc.) or other applications that include at least one relatively soft (e.g., padded or cushioned) portion formed by a partial-mold-behind (PMB) process that also has stitching (decorative or functional).

It is generally known to provide padded or cushioned vehicle interior components with stitching. Such stitching may be decorative/ornamental and/or functional. The padded or cushioned vehicle interior components may take the form of a trim panel (e.g., instrument panel, door panel, etc.). Such panels typically include a substrate made of a relatively rigid material, a relatively soft core (e.g., a foam layer), and an outer surface or skin. Various methods of providing such cushioning and stitching are known in the art, although such known methods do not provide certain advantageous features and/or combination of features. For example, it is known to add stitching to interior components to the skin (or skin and foam laminate) and then attach the skin to the substrate by a hand or manually wrapping technique. It is also known to apply the stitching after the interior component has been formed (e.g., after the skin, foam, and substrate has been joined). However, such known methods of applying decorative stitching are labor-intensive or do not provide the desired visual effect of depth that would be provided by a recessed stitch (e.g., “quilting” or cushioning effect that provides contour change in the soft surface). Therefore, such recessed stitching provided by known costly manufacturing processes are typically only available on premium or luxury class vehicles.

Accordingly, there is a need to provide a method for producing components such as panels or other structures for use in vehicles that includes a relatively soft portion or section with decorative stitching. There is also a need to provide a component that has regions of localized cushioning with decorative stitching that has a recessed stitch. There is also a need to provide an economical process of manufacturing trim panels with recessed stitching for less expensive vehicles. There is also a need to provide components and a method for making components that may be manufactured in a relatively simple and efficient manner with reduced manufacturing and material costs.

The present invention further relates to various features and combinations of features shown and described in the disclosed embodiments.

SUMMARY

One embodiment of the invention relates to a method of forming a vehicle trim panel. The method comprises forming a flexible skin; coupling a compressible material to the skin; providing a stitching to the skin and compressible material combination; then positioning the coverstock in a mold; compressing the compressible material by introducing plastic to the mold to form a rigid substrate that is bonded to the coverstock and the stitching; and removing the panel from the mold so that the compressible material can expand around the stitching and provides a first soft region wherein the compressible material is disposed between the skin and the substrate so that a first soft region is defined by the compressible material. The stitching may also be provided to the skin that is not coupled to a compressible material layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a door trim panel having a cushioned region with stitching.

FIG. 2 is a fragmentary perspective section view of the door trim panel of FIG. 1 taken along the line 2-2.

FIG. 3 is a fragmentary perspective section view of the door trim panel of FIG. 1 taken along the line 3-3.

FIGS. 4-6 are schematic views of exemplary embodiments of a method of forming a trim panel having a coverstock with embedded stitching.

FIG. 7 is a schematic view of an alternative embodiment of a coverstock with stitching positioned in a mold after injection of a plastic to form the substrate.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates one exemplary embodiment of a component or assembly such as a panel or other structure for use in a vehicle (e.g., automobiles such as cars, trucks, buses, and the like; airplanes, boats, etc.). Such components may be provided in a wide variety of sizes, shapes, and configurations according to various exemplary embodiments. For example, such components may be utilized in an interior passenger compartment of a vehicle, and may find utility in the form of door panels, dashboards, instrument panels, consoles, sidewall trim, overhead liners, or other vehicle components or portions thereof. The exemplary component is a door panel 100 and includes one or more localized or discrete portions 112 (e.g., areas, regions, etc.) of softness or cushion that have stitching 113 (e.g., seam, embroidery, and/or other sewn portion, which will collectively be referred to as stitching 113). The door panel is provided with cushioning in portions 112 where a portion of a passenger's body may or is likely to contact the door (e.g., on an armrest 114, adjacent a window sill 116, etc.) without the need to provide cushioning in the entire door. For example, the door panel also includes one or more portions 118 (e.g., areas, regions, islands, etc.) of hard plastic in areas not typically contacted by a passenger. Stitching 113 may provide any of a variety of or combination of decorative, ornamental, and/or functional purposes.

The methods of providing localized cushioned portions 112 of softness or cushioning in a manner described herein may be utilized to provide components having a wide variety of configurations and uses. Portion 118 may include bezels, accents, appliques, pull cups, complex geometries (e.g., ball armrests, x, y, z boundaries, etc.), proud (e.g., raised) or recessed regions of cushioning for enhanced aesthetics, or the like.

Referring to FIGS. 1-3, door panel 100 includes a member or element in the form of a relatively rigid substrate, base, or stratum (referred to herein as a “substrate” 120). Cushioned portion 112 is located adjacent or proximate to at least a portion of substrate 120, and comprises a coverstock 110 coupled to substrate 120. According to an exemplary embodiment, coverstock 110 comprises a skin 122 and a filler or compressible material 124 provided intermediate or between skin 122 and substrate 120. According to exemplary embodiments, portions of skin 122 may be in direct contact with substrate 120 (i.e., no compressible material 124 between skin 122 and substrate 120 such as shown in FIG. 7), while other portions of skin 122 may be separated from substrate 120 by compressible material 124. In this manner, selectively varying amounts or degrees of softness or cushioning are provided at one or more localized regions while retaining the look and feel of the skin even in those regions not provided with the additional cushioning of compressible material 124. The particular design chosen may depend on any of a variety of factors, including the desired look and feel of the outer surface of the panel, materials costs, ease of manufacturing, etc.

According to an exemplary embodiment, the cushioned portion 112 is disposed on or over at least a portion of substrate 120. Skin 122 forms at least a portion of the exterior surface (e.g., the portion visible from a passenger compartment, which is typically referred to as the “A” surface or side) of the component. According to an exemplary embodiment, a portion 126 of substrate 120 not covered by coverstock 110 may also form a portion of the exterior surface (“A” surface). Referring to FIG. 3, a boundary 128 between substrate 120 and skin 122 may be provided in the form of a seam, interface or joint, or the like. Such boundary 128 may be visible at the exterior surface (“A” surface) or may be eliminated or reduced in size by being filled in with a material (e.g., a caulk, adhesive, liquid polymer, or other materials) to provide a “seamless” look for the component at the interface of skin 122 and substrate 120. As shown in FIGS. 1 and 3, boundary 128 is formed or provided so that substrate 120 forms a frame around skin 122. The size, shape, and configuration of boundary 128 may vary in various exemplary embodiments. FIG. 3 illustrates one exemplary embodiment showing the coupling between the skin and the substrate.

Any of a variety of configurations may be utilized for the interface of the edges of the skin and the substrate. According to an exemplary embodiment, a flange 130 is formed on skin 122 by forming in a vacuum mold (e.g., to provide an edge of the skin with a “folded back” configuration to form a protrusion). Substrate 120 is then molded around flanges 130 of skin 122 (and compressible material 124). According to a preferred embodiment, skin 122 and substrate 120 are coupled together such that a relatively airtight and/or watertight seal is provided. In one example, the skin includes flanges 130 that extends substantially entirely about the periphery of skin 122, and substrate 120 is molded around flanges 130 to at least partially encapsulate the flange 130 (e.g., to form a channel or groove that extends substantially entirely about the periphery of the area over which skin 122 is provided and receive the flanges 30). Various sizes, shapes, and configurations may be used for the protrusion or flanges and the opening or groove to couple skin 122 to substrate 120.

Substrate 120 provides a base or support layer for skin 122 and compressible material 124. Substrate 120 may be made of any suitable material, including any of a variety of polymers (e.g., polypropylene, polyethylene, copolymers, compressed fibers, TPO, filled plastics, polycarbonate ABS blends, ABS, or any of a variety of other materials). Substrate 120 may be formed in any of a wide variety of shapes, sizes, and configurations (see, e.g., FIG. 1, which shows door panel 100 according to an exemplary embodiment having regions of localized cushioning), and may include a variety of other features (e.g., apertures for door locks and handles, molded-in designs, etc.). Substrate 120 may be formed by any of a variety of methods, including injection molding, thermoforming, or the like. Portions of substrate 120 that form part of the “A” surface may have any of a variety of textures, colors, indicia, features, and the like. Substrate 120 may be a stand-alone component or may be a component in a larger assembly (e.g., the substrate may be an entire door panel or may be a portion thereof, etc.).

According to an exemplary embodiment, skin 122 is made of a relatively soft or flexible material comprising a polymeric material (e.g., a thermoplastic olefin (TPO), polyurethane, polyvinylchloride (PVC), etc.). According to other exemplary embodiments, skin 122 may be made of other materials, including textiles such as cloth, leather, composite materials, layered materials (e.g., a layer of leather applied above a polymeric material layer), etc. Skin 122 may have a size, shape, and configuration that is adapted or configured to features included in substrate 120. Skin 122 may be manufactured or produced utilizing any of a variety of process. According to a preferred embodiment, skin 122 (e.g., a TPO sheet) is thermoformed (e.g., vacuum formed, pressure formed, etc.) and then trimmed to a desired shape or configuration. In a vacuum molding process, a pre-cut or formed sheet of polymeric material is provided in a mold and heated to soften the material. A vacuum is applied to the mold, which draws the softened polymeric material toward the walls of the mold. The polymeric material then cools and maintains the shape defined by the mold walls. The formed sheet may also be trimmed for desired size. According to an alternative embodiment, the skin is formed by a slush molding process wherein thermoplastic material in a liquid or powdered form is introduced into a temperature-controlled mold to form a viscous skin adjacent to the mold walls; once the skin is formed, the excess material is removed from the mold and the skin is allowed to cure and cool, after which the skin is removed from the mold. According to other alternative embodiments, skin 122 is manufactured according to various other methods. For example, the skin may be formed in an injection molding process, an extrusion process, a casting process (e.g., gravity casting), or any other suitable process for forming a polymeric skin. According to an exemplary embodiment in which skin 122 is made of a polymeric material, the skin has a thickness of between approximately 0.1 and 2.0 millimeters, and most preferably between approximately 0.8 and 1.0 millimeters.

According to an exemplary embodiment, compressible material 124 is coupled (e.g., bonded, fused, adhered, fastened, attached, etc.) to skin 122 and located in between skin 122 and substrate 120 to act as a “filler” or soft layer. It is intended that such material acts as a relatively soft or cushioning material to provide the cushioned member with at least a portion of its relatively soft or cushioned characteristic. According to a preferred embodiment, the compressible material is a polymeric material such as a foam material (e.g., urethane foam, closed cell foam, open celled foam, etc.). According to an alternative embodiment shown in FIG. 7, stitching 113 is applied to skin without having a compressible 124 (i.e., to provide a different level of softness). As such, stitching 113 may be provided to skin 122 with compressible material, skin 122 without compressible material 124; and the thickness of the skin layer and the compressible material layer may be varied according to the desired softness.

According to a preferred embodiment, skin 122 is coupled to the substrate 122 so that the compressible material 124 (if any) is located intermediate or between at least a portion of skin 122 and at least a portion of substrate 120. As such, the “A” surface of the door panel may be provided by at least a portion of substrate 120 and/or at least a portion of skin 122.

According to a particular exemplary embodiment, door trim panel 100 shown in FIG. 5 includes an integrated bolster and armrest. This embodiment utilizes a die-cut, compressible filler material 124, such as a die-cut closed cell foam attached (via pressure sensitive adhesives or like processes) to the vac-form skin 122. The part is then placed into a tool and plastic is molded around the assembly to form substrate 120. Where the compressible material 124 (and skin 122) is present, there is a soft compressible feel to the part. Where there is no compressible material 124 behind skin 122, there is a harder feel to the part.

Stitching 113 is applied to skin 122 or (preferably) to a laminate of skin 122 and compressible material 124. Stitching 113 may be applied by any of a variety of conventional techniques (e.g., hand sewn, machine sewn, etc.). Stitching 113 may be made from any of a variety of materials, such as fabric, textile (e.g., cotton), polymer (e.g., nylon, etc.), or other material which may or may not melt or liquify upon application of heat. Applying stitching 113 to the laminate of skin 122 and compressible material 124 (or to just skin 122) before substrate 120 is molded is intended to recess stitching 113 in skin 122 and/or compressible material 124. During molding of substrate 120 as shown in FIGS. 4-6, compressible material 124 is compressed by the injection of the molten resin that forms substrate 120. Stitching 113 compresses less (and preferably substantially less) than compressible material 124 and/or skin 122 such that skin 122 and compressible material 124 are forced around stitching 113. During the molding process, substrate 120 bonds (e.g., mechanically and/or chemically (e.g., thermally or fusion)) to stitching 113. When the molded article is removed from the mold tool or fixture, compressible material 124 expands away from substrate 120 (and around stitching 113) to provide the visual effect that stitching 113 is recessed (e.g., providing a “quilting” or a contour change with the appearance that that portion of the trim panel is cushioned).

According to an exemplary embodiment, a method of forming the trim panel comprises forming the flexible skin 122; coupling the compressible material 124 to skin 122; applying the stitching 113 to skin 122/compressible material 124 laminate; die cutting skin 122/compressible material 124 to a desired shape (if necessary); positioning skin 122 and compressible material 124 in a space or gap 138 of a mold 140; and forming rigid substrate 120 around skin 122 and compressible material 124 providing a first soft region 112 wherein the compressible material 124 is disposed between skin 122 and substrate 120 so that a first soft region 112 is defined by the compressible material 124. As the plastic material or resin is injected into the space 138, compressible material 124 is compressed from the pressure of the injected plastic. As the panel 100 is removed from mold 140, compressible material 124 expands around stitching 113 to provide the desired appearance.

According to exemplary embodiments shown in FIGS. 4-6, the method comprises a partial mold-behind process where skin 122 with stitching 113 (and compressible material 124 as prescribed) provide a portion of the A-surface of the molded article (i.e., the side of the molded article that is visible to the vehicle occupant). Mold 140 comprises a first mold section (shown as a core 142) and a second mold section (shown as a cavity 144). Cavity 144 includes a projection 146 (e.g., blade, member, pin, etc.) comprising a thin member extending from cavity 144. Coverstock 110 is coupled to cavity 144 (e.g., suspended from pins held in place by clamps, thrust members, or the like), and mold 140 is closed. According to an alternative embodiment, the coverstock is coupled to the core. Melted resin is injected into space 138 between the mold sections and presses or forces coverstock 110 against the cavity 144. Projection 146 maintains the edge of coverstock 110 in place so plastic flows around it to form a recess or boundary 128. Edges of coverstock 110 may also then be wrapped and coupled to substrate 120 (e.g., tacked, welded, fastened, bonded, joined, etc.). According to an exemplary embodiment, the process further includes forming the recess in the substrate and encapsulating at least one edge of the coverstock within the molten polymeric material that forms a portion of the substrate that defines the recess. A portion of the stitching may be encapsulated (e.g., captured, bonded to, coupled to, etc.) by the molten polymeric material.

It is also important to note that the construction and arrangement of the elements of the vehicle trim panel as shown in the preferred and other exemplary embodiments are illustrative only. Although only a few embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, the compressible material may be coupled to the skin and positioning the skin and compressible material in a mold; and forming a rigid substrate around the skin and compressible material providing a first soft region wherein the compressible material is disposed between the skin and the substrate so that a first soft region is defined by the compressible material. Stitching may be provided on either the portion of the skin adjacent the first shot, or the second shot, or the third shot, or the like. The substrate may comprises a molded polymer material such as a thermoplastic. The skin may comprise a thermoplastic olefin and be formed by vacuum forming and trimming a sheet. The compressible material may comprise a foam material such as a closed cell foam. The skin may comprise flanges so that the substrate can be molded to at least partially encapsulate the flanges. A second soft region may be defined by a portion of the skin in direct contact with the substrate (e.g., the compressible material is not disposed between the skin and the substrate). The molding technique may also be employed in other application besides for vehicle interiors. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and/or omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention as expressed in the appended claims. 

1. A method of forming a trim panel for a vehicle comprising: providing a coverstock comprising a skin layer and a compressible layer; adding a stitching to the coverstock; positioning the coverstock in a mold; compressing the compressible material by introducing a molten polymeric material to the mold to form a rigid substrate that is bonded to the coverstock and the stitching; and removing the panel from the mold so that the compressible material can expand around the stitching.
 2. The method of claim 1 wherein the skin layer is formed by vacuum forming and trimming a sheet.
 3. The method of claim 2 wherein the skin layer is thermoplastic olefin.
 4. The method of claim 1 wherein the compressible layer is coupled to the skin layer.
 5. The method of claim 1 wherein the compressible layer comprises a foam material.
 6. The method of claim 5 wherein the foam material is a closed cell foam.
 7. The method of claim 5 wherein the foam material is bonded to the skin layer.
 8. The method of claim 1 wherein the trim panel is a door trim panel.
 9. The method of claim 1 further comprising providing a second soft region defined by a portion of the skin layer that is in direct contact with the substrate.
 10. The method of claim 1 wherein the step of forming the substrate comprises injection molding a thermoplastic material.
 11. The method of claim 1 further comprising the step of forming a recess in the substrate and encapsulating at least one edge of the coverstock within the molten polymeric material that forms a portion of the substrate that defines the recess.
 12. The method of claim 1 wherein a portion of the stitching is encapsulated by the molten polymeric material.
 13. The method of claim 1 wherein the step of compressing the compressible material results in the compressible layer being in direct contact with the rigid substrate.
 14. The method of claim 13 wherein the step of compressing the compressible material results in the skin layer being in direct contact with the compressible material.
 15. The method of claim 1 wherein the step of compressing the compressible material results in the skin layer being in direct contact with the compressible material and the rigid substrate. 